Method and apparatus for casting engine blocks



A. J. MEYER April 30, 1935'.

' METHOD AND APPARATUS FOR CASTING ENGINE BLOCKS Filed May 28. 193 6 Sheets-Sheet 1 IIIIIIIIIII/IIIIIII/WIIIA & INVENTOR. Andre J/Waqr ATTORNEY.

A. J. MEYER April 30, 1935.

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A. J. MEYER April 30, 1935.

METHOD AND APPARATUS FOR CASTING ENGINE BLOCKS Filed May 28, 1951 6 Sheets-Sheet 3 IN VEN TOR. We?

ATTORNEY.

A. J. MEYER April 30, 1935.

METHOD AND APPARATUS FOR CASTING ENGINE BLOCKS I Filed May 28, 1931 6 Sheets-Shet 4 0 I ENTOR.

' N flvire 1/. Myer 4 ATTORNEY.

April 30, 1935. A. J. MEYER 1,999,511

METHOD AND APPARATUS FOR CASTING ENGINE BLOCKS Filed May 28, 1931 6 Sheets-Sheet 5 6 Sheets-Sheet 6 A. J. MEYER Filed May 28, 1951 METHOD AND APPARATUS FOR CASTING ENGINE BLOCKS I April 30, 1935.

INVENTOR. J zmfiz Q7. m

ATTORNEY.

atented A r. so, 1935 1,999,511

APPARATUS run CdSG ENGINE BLWDKfi Andre .i. Meyer, Detroit, Mich, assignor Comtinental Motors Corporation, Detroit, ch... a corporation at Virginia I Application May 2%, i931, Seriai No. with 115 (Claims. (Ci. 22ll33) My invention relates to a method and appacessity of relatively expensive and complicated ratus for casting engine elements or parts and port machining operations. more particularly relates to a novel method and In carrying out my invention I provide a port apparatus for casting engine blocks. core preferably forming a unitary assembly with A method and apparatus such as hereinafter coope at n y de Cores whereby all Ports d 5 described is especially adapted for use in castpassages therefor, in the illustrated embodiment ing the engine block of a sleeve valve internal are definitely fixed in accurate location with recombustion engine provided with a multiplicity p t t a h t r and to t r c p at pa ts of cylinders having a plurality of intake and exf e engine Castihgy invention provides haust ports and passages arranged to xt d for accurate location of the port passages al- 10 through the side walls of the cylinders. The though this is of Secondary p tan Since hereinafter described method and apparatus is minor variations of uc p a s a e not of mamore particularly adapted for casting the engine terial consequence compared with the location block of an engine of the Burt-McCollum type of the intake and exhaust P ts. provided with a single sleeve valve having a com- For a more detailed understanding of y 15 bined reciprocating and oscillating movement V n reference y he had to the ac p nywith respect to'the cylinder and sleeve axes in ing drawings Which illustrate One m which which any point on the sleeve traverses a closed my invention y assume, and in w ch: path Figure 1 is a disassembled view of the baked One of the difiiculties in manufa t ri sleeve sand core elements shown in the relative order 20 valve engines of the type as specified-above is of their assembly, the relatively expensive machining operations Figure 2 is an assembled w O Sa d ba ed generally employed in machining the cylinder insand core elements and showing same assembled take and exhaust ports. Difliculty has also been 'i a flask and Sand mold drag, experienced in properly aligning various cores Figure 3 illustrates the next step in assembling 25 and patterns employed with the general type the mold and Showing the p flask and c p of apparatus used for casting cylinder blocks, port sembled With the Structure Shown in Figure passages, or other engine parts and elements. Figure 4 is a transverse Sectional w through Heretofore it was customary to provide cores an engine block Cast in accor a c wi y STT OFFICE supported from the exterior of the engine mold Ventlon and taken 0n the line of Figure 30 for casting the passages leading through the 03 1- Figure 5 s a z nta fra m ta y s ti nal inder walls, the orts in the cylinder walls being view taken on the line of ure 4 t rou h thereafter machined to accurately fix their dethe ports d po t passa sired location with respect to the cylinder axis. Figures 6 a d 7 a e sectional views taken re- Heretofore the customary practice resulted in Specllively on the lines and 0f Figure 35 casting orts and passages whereby t ports Figure is a sectional view taken on the line would not lie in the desired common plane perof Figure 6, pendicular to the axis of the cylinder, owing to Flgulje 9 a Plan new of the Structure the tendency of the port cores to shift and the Hated m Figure absence of any unitary core structure embodyf i ?%w the outer core as seen 40 ing the cylinder and port cores such as provided gig E g n the intermediate core by my inven ion. Fig. 12 1s a plan View of the crankcase core It is an obJect of my present invention to de- 4 crease the manufacturing costs of internal comc fg i 1S plan View of the outer water Jacket bustion engines and in particular multi-cylinder engines of the sleeve valve type by providing an 2 14 1S plan View of the Inner water jacket improved method and apparatus for casting the engine block.

Another object of my present invention is to facilitate the manufacture Of internal combus- Burt McC 11um type operating in a manner we tion engines of the sleeve valve type by providing known in the art, Figures 4 and 5 illustrating an a novel method d pp a o Casting an engine block casting constructed by the novel engine cylin er block with cast cylinder intake means, method and apparatus hereinafter de- 5 and exhaust ports thereby eliminating the nescribed. This block in general consists of a 55 In the accompanying drawings I have chosen to illustrate my invention in connection with a sleeve valve internal combustion engine of the crankcase l0 having crankshaft bearing portions H and valveshaft bearing portions l2. The cylinder or cylinders 3 are integrally formed with the crankcase and are provided with suitable water jackets |4 and intake and exhaust ports I5 and I6 respectively and their cooperating intake and exhaust port passages l5 and I6 respectively.

The above described casting is produced and constructed in such a way as to eliminate the necessity of machining the intake and exhaust ports I5 and I6, and furthermore the novel means and apparatus by which this casting is formed makes possible the construction of a casting having cylinders, ports and other component parts of the casting properly located and aligned with respect to each other.

The casting is formed by employing a plurality of cooperating baked sand cores which are assembled together and fitted within a green sand mold in a manner which will hereinafter be described. The baked sand core structure includes a top or outer core 20, a port core 2|, a crankcase core 22 and the outer and inner water jacket cores 23 and 24 respectively. The cores 23 and 24 .provide a tubular cylinder. The cores 20, 2|,23

and 24 preferably form the aforesaid unitary assembly, these cores being preferably glued together and fused into a unitary assembly, prior to assembly in the mold. The cores forming the assembly will be described in detail hereinafter, and if desired they may be separately assembled in the mold rather than prior as aforesaid.

Figure 1 illustrates the relative position of these cores during assembly and it will be noted that the port core 2| is interposed between the top or outer core and crankcase core 20 and 22 respectively, the water jacket cores 23 and 24 being respectively supported in the core 20 and the green sand molds associated therewith. Suitable chaplets (not shown) may be used between cores 23 and 24 and the green sand of the bottom flask 21. Such chaplets are well known in the art. When the metal is poured into the mold the boss 43 (see Fig. 1) of jacket core 24 prevents this core 24 from floating upwardly from its proper position. The adjoining faces of these baked sand cores are ground or otherwise finished so that they will fit together properly and are so constructed that they are properly positioned relative to each other in accurate alignment when assembled together. Said cores and molds when assembled are thus spaced to provide metal thickness spaces.

In the illustrated embodiment the port core 2| carries projections or extensions 38 for casting the ports l5, I6 and also port passages l5 and l6 although the core portions for the port passages may be separately formed and supported from the outside. However, the illustrated embodiment is preferred for a more complete attainment of the objects of this invention.

The assembled baked sand core structure composed of the elements 28 to 24 inclusive are inserted into the mold 25 formed in the green sand within the bottom flask 21, said green sand mold being commonly known as the drag and constructed in a well known manner from the usual patterns prior to cooperative assembly with the baked sand core structure. A green sand mold or cope 28 contained within the upper flask 29 is cooperatively associated with the core structure as shown in Figure 3. Pins 30 are preferably carried by the bottom flask and are adapted to engage in recesses 3| carried by the flange 32 of the upper flask for locating the upper flask relative to the lower flask.

The following steps are taken in constructing the baked sand cores. The top or outer core 20 is provided with a boss 9 in the recessed portion 8 of the core. This core 20 is formed and baked and is put into any suitable fixture for final shaping, the boss 9 locating the core within the fixture in such a manner that the top or outer surface 1 of the core may be ground or otherwise finished to the desired dimension. Next the inner or bottom surface 33 of the outer core 20 is ground orv otherwise finished substantially parallel to the upper surface I and accurately located with respect to the boss 9. This core 20 is provided with a plurality of recesses 34 adapted to receive projections 35 of the water jacket core 23 and to locate this water jacket core in spaced relation within the recess 8 of the top or outer core 20.

Next, the port core 2| is adapted to be seated against the lower or inner face of the top or outer core,.this port core 2| having outer and inner finished surfaces 36 and 31 respectively said surfaces being ground or otherwise finished while the said port core is supported in a suitable jig or fixture (not shown), this fixture being constructed in a manner well known in the art and arranged to locate the core projections or extensions 38 which form the port openings in such a way as to properly space said port openings relative to the face of the boss 9. Preferably the outer and inner surfaces 36 and 31 are ground while the port core is held within a fixture associated therewith, (this fixture not being shown since any suitable fixture constructed in a manner well known in the art may be employed for this purpose) these surfaces being accurately spaced from the core projections or extensions 38. The port core 2| and top or outer core 20 are preferably secured by cementing the same together and locking said cores from displacement by a lead plug 39 as shown in Figure 2 this lead plug being formed by pouring molten lead into thecooperating recesses 40 and 4| carried respectively by the port core 2| and top or outer core 20. The water jacket core 24 is next positioned in place to abut the water jacket core 23, said jacket cores being formed with recesses 42 in their adjoining faces for spanning the core projections or extensions 38 which form the port openings in the finished casting.

The construction above described is especially applicable to a multi-cylinder engine of the sleeve valve type, the core projections or extensions 38 being adapted to form port openings in the cylinder walls of the finished casting as shown in Figure 4, said port openings being designated l5 and I6 and adapted to cooperate with the intake and exhaust ports of an associated sleeve valve means (not shown). The water jacket core- 24 is provided with a plurality of bosses 43 which are adapted to fit within corresponding recesses in the green sand molds 25 and 28, and to be thus properly located with respect to the other cores forming the core structure. Preferably the top or outer core 20 and the port core 2| extend the full length of the engine and each are constructed to form a plurality of cylinders according to the desired number of cylinders for the engine. The core 28 is provided with a plurality of barrel shaped portions 44 which form the upper part of the respective cylinders and as shown in the accompanying drawings the core 20 is provided with a sufficient number of these barrel reeasii 3 portions N in order to provide cores for the entire number of cylinders employed in the engine.

However, if desired, the top or outer core could be made of two or more pieces and suitably joined together, though it is preferred to employ the construction shown in the illustrated embodiment of my invention. Likewise the port core 2|] is preferably constructed substantially as shown in the drawings and preferably provides a core for cooperative association with a plurality of cylinders, preferably extending the full length of the engine casting. If desired this port core may be made in two or more sections in order to avoid dimculties in forming and handling this core, particularly in engines having a relatively large number of cylinders-in-line. If desired separate port cores for each cylinder may be provided.

The crankcase core 22 is of a relatively larger size and in order to facilitate the assembly of same with the port core the crankcase core is preferably constructed of a plurality of sections. This crankcase core 22 is provided with the outwardly extending barrel portions which are spaced longitudinally of the engine and each of said portions t5 may be provided with a tapered pilot portion it, the pilot portions being adapted to preferably seat within tapered recesses fl'l carried by the port core'tl. Thus the barrel portions M and W are coaxially aligned with respect to each other and with respect to the axis of the port core 2 i.

It will thus be noted that the port openings in the finished casting are accurately located with respect to the outer finished face of the casting and preferably with respect to the recess t8 formed in said castings by the bosses The cylinder block casting formed by the above green sand molds and baked sand cores is adapted to be located in any suitable jig or fixture (not shown) by locating the inner surface of the machining locating recess 48 on suitable supports. When the casting is thus fixed in the fixture which supports the same, the bottom or inner faces of the bearing cap may be machined and suitable holes formed which may be employed for locating the casting in another suitable fixture (not shown) at which time the other faces of the casting may be machined.

The port care 2!! preferably extends substantially the entire length and width of the engine.

Figure 6 illustrates the principle of my invention as incorporated in an apparatus for casting the engine block structure of a sleeve valve internal combustion engine, the port core 2i being constructed substantially of a single core, and arranged to form a one piece core for a multiplicity of cylinders. 1

It will be noted that the top or outer core 20 and the port core 2i are constructed in such a way as to form a portion of the outer wall of the engine block casting, especially that portion of the casting in the vicinity of the ports and to the outside or above that portion of the casting in the vicinity of the ports.

Portion 38 of the port core 2!! which forms the ports is accurately located with respect to the boss 9 due to the fact that the inner surface 33 of the top or outer core is first accurately located with respect to said bosses 9 and the outer finished face 36 of the port core is arranged to seat on said inner surface or face 33.

elhen the cooperating green sand molds and baked sand cores are assembled in the relation shown in Figure 3, the molten metal is poured through a suitable hole or gate 60 and when the metal has set, the green sand is knocked oil and the cores are removed in the usual manner.

The baked sand cores are supported on the green sand, cores 20 and 2t resting on the fiat surface Iii in the drag 25 and the crankcase core 22 resting on the surface it in the drag 25.

The casting produced by the means, method and apparatus above described may be economically machined or otherwise finished with a minimum of time and labor.

Although I have illustrated but one form of my invention and have described in detail but a single application thereof, it will be apparent to those skilled in the art to which my invention pertains that various modifications and changes may be made therein without departing from the spirit of my invention or from the scope of the appended claims.

What I claim as my invention is:

1. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, the combination of a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly within said mold cavity and including a plurality of core parts providing a cylindrical surface, said core parts constructed to providea metal thickness space associated with said cylindrical surface, one of said core parts having port shaped projections extending transversely of said metal thickness space, said core assembly also including a cylindrical tubular core 13 structure spaced between said cooperating core parts and said green sand mold.

2. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, the combination of a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly within said mold cavity and including a plurality of core parts providing a cylindrical surface, said core parts constructed to provide a metal thickness space associated with said cylindrical surface, one of said core parts having port shaped projections extend? ing transversely of said metal thickness space, said core assembly also including a pair of cylindrical tubular core elements spaced with respect to said cylindrical surface, said core elements having cooperating recessed portions enclosing said port shaped projections.

3. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, the combination of a cope and drag formed of green sand and cooperating'to provide a mold cavity, a core assembly within said mold cavity, said core assembly including a core part at one end thereof cooperating with said mold cavity to provide a metal thickness space adapted to form the engine crankcase, said core assembly including a core part having a cylindrical surface associated with said cavity and constructed to provide a metal thickness space substantially surrounding the cylindrical surface, said assembly also including a port forming core extending laterally from said cylindrical core .part transversely of said metal thickness space.

4. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, the combination of a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly within said mold cavity, said core assembly including a core P part at one end thereof cooperating with saidmold cavity to provide a metal thickness space adapted to form the engine crankcase, said core assembly including a core part having a cylindrical surface associated with said cavity and constructed to provide a metal thickness space substantially surrounding the cylindrical surface, said assembly also including a port forming core having a plurality of projections extending laterally from said cylindrical core part transversely of said metal thickness space.

5. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, said mold comprising a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly supported within said green sand mold cavity, said core assembly including a core part at one end thereof cooperating with said mold cavity to provide a metal thickness space adapted to form the engine crankcase, said assembly including a cylindrical core part, a port forming core extending laterally from said cylindrical core part, and a tubular cylindrical core structure for forming the engine cylinder water jacket and spaced from said cylindrical core part and cooperating with the mold cavity to provide a metal thickness space around said cylindrical core, said port forming core extending transversely of said last mentioned metal thickness space, and projecting through the walls of said tubular cylindrical core structure.

6. In a mold for casting the engine block of an internal combustion engine having a cylinder provided with sports, a cope and drag formed of green sand and cooperating to provide a mold cavity, a baked core structure supported within said mold cavity and consisting of a plurality of cooperating core sections, said core sections having coaxially aligned cylindrical portions forming a continuous cylinder core, one of said core sections having laterally projecting port forming projections, and a cylindrical tubular cylinder water jacket forming core structure surrounding said cylinder core, said tubular core structure consisting of a pair of core elements having adjoining end faces extending generally in the plane of the laterally projecting port forming core portions, said core sections cooperating together and with said mold cavity to provide a metal thickness space, said port forming projections extending transversely of the metal thickness space.

7. In a mold for casting the engine block of a multi-cylinder internal combustion engine having ports in the cylinders, a cope and drag formed of green sand and cooperating to provide a mold cavity, a baked sand core structure supported within said mold cavity and including a plurality of associated core parts consisting of an outer core having a plurality of cylindrical core parts adapted for forming a plurality of cylinders, an intermediate core part seated on said outer core and having laterally extending projections adapted to form said ports in the casting, a core structure seated on the inner face of said intermediate core and adapted to form the engine crankcase, and a multi-part core structure adapted to form a cylinder jacket, one part of said jacket forming core extending outwardly from said port forming core part and supported in spaced relation with said outer core and port forming core part, and another part of said jacket forming core extending inwardly from said port forming core part and supported in spaced relation with said crankcase forming core and said port forming core part, whereby to provide a metal thickness space, said laterally extending projections extending transverse of said metal thickness space.

8. In a mold for casting cylinder blocks of engines of the sleeve valve type, a cope and drag formed of green sand and cooperating toprovide a mold cavity, an inner cylindrical core structure adapted to form the cylinder wall of the engine, an outer core structure having a portion thereof spaced from said inner cylindrical core structure for forming the outer portion of the engine cylinder block, a cylindrical tubular core structure spaced intermediate said inner cylindrical core structure and said outer core structure and provided with openings laterally therethrough, said tubular core structure adapted to form 9. cylinder jacket, said openings being spaced circumferentially in a plane substantially perpendicular to the axis of said inner cylindrical core structure, said core structures cooperating together and with said mold cavity-to provide a metal thickness space, said inner cylindrical core structure having core projections extending transverse of said metal thickness space and through said openings in spaced relation therewith to form ports through said cylinder wall and said cylinder jackets.

9. In a mold for casting cylinder blocks of engines of the sleeve valve type, a cope and drag formed of green sand and cooperating to provide a mold cavity, an inner cylindrical core structure adapted to form the cylinder and inner crankcase walls of the engine, an outer core structure having a portion thereof spaced from said inner cylindrical core structure for forming an outer portion of the engine cylinder block, a cylindrical tubular core structure spaced in part intermediate said inner cylindrical core structure and said outer core structure and provided with openings laterally therethrough, said tubular core structure adapted to form a cylinder jacket, said openings being spaced circumierentially in a plane substantially perpendicular to the axis of said cylindrical core structure, said core structures cooperating together and with said mold cavity to provide a metal thickness space, said inner cylindrical core structure having'core projections extending transverse of said metal thickness space and through said openings in spaced relation therewith to form ports through said cylinder walland said cylinder jacket, said inner core structure also having an outer portion adapted to form the outer portion of the engine cylinder during the casting operation, said outer portion extending toward the crankcase forming core portion for cooperation with said core projections, and means connecting said core projections and said outer portion of the inner cylindrical core structure.

10. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, a cope and drag formed of green sand and cooperating to form a mold cavity, av

core assembly within the mold cavity, said assembly including a core part at one end thereof cooperating with the mold cavity to provide a metal thickness space adapted to form the engine crank case, said assembly including aligned cylindrical core parts spaced within said mold cavity, said assembly including cooperating cylindrical tubular core parts forming a cylinder Water jacket and arranged concen ric with and spaced from said cylindrical core parts and from said mold cavity whereby to provide metal thickness spaces adapted to form a cylinder jacket, and a plurality of laterally extending core projections extending transversely of the last mentioned metal thickness spaces through said cylindrical tubular core parts to said cylindrical core parts whereby to form port passages through said cylinder jacket.

11. In a mold for casting the engine block of a multi-cylinder internal combustion engine of the type having ports in the walls of the cylinders, a cope and drag formed of green sand and cooperating to provide a mold cavity, a baked sand core structure supported within the mold cavity and consisting of an outer core having a plurality of inwardly extending cylindrical core parts, a port forming core part formed with cylindrical portions each aligned with one of said inwardly extending cylindrical core parts, said core parts cooperating together and with said mold cavity to provide a metal thickness space, said port forming core part provided with laterally extending projections constructed to extend transversely of the metal thickness space to form said ports in the casting.

12. In a mold for casting the engine block of a multi-cylinder internal combustion engine having ports in the cylinders, a cope and drag formed of green sand and cooperating to provide a mold cavity, a baked sand core structure. supported within the mold cavity and consisting of an outer core having a plurality of inwardly extending longitudinally spaced cylindrical core parts and an inwardly extending outer core portion laterallyspaced from said cylindrical core parts, a port forming core part extending in contacting relation with said cylindrical core parts, said core parts cooperating together and with said mold cavity to provide a metal thickness space, said port forming core being provided with laterally extending projections extending transversely of the metal thickness space and bridging the space between said inner and outer core parts whereby to form said ports in the casting.

13. In a mold for casting the engine block of a multi-cylinder internal combustion engine having ports in the cylinders, a cope and drag formed of green sand and cooperating to provide a mold cavity, a baked sand core structure supported within the mold cavity consisting of an outer core having a plurality of radially spaced concentrically arranged cylindrical core parts adapted for forming a plurality of cylinders, and a port iorming core part associated with said outer core and supported in contacting relation with said core parts, said core parts cooperating together and with the mold cavity to provide a metal thickness space, said port forming core part having projections extending laterally of said cylindrical core parts transversely of the metal thickness space and bridging the space between said radially spaced core parts for forming said ports in the casting.

14. In a mold for casting an internal combustion engine cylinder block having ports inthe cylinder walls, a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly within said mold cavity and including an outer core portion having a cylindrical extension associated therewith and spaced within said cavity, said assembly including a plurality of additional core portions cooperating with said cylindrical extension of said outer core portion to provide a cylindrical surface, said assembly further including a jacket core structure lying within said mold cavity and spaced radially outwardly from said cylindrical surface, one of said additional core portions having a port shaped projection associated therewith and extending through said jacket core structure, said outer core portion having a part associated therewith and extending in substantially the same direction as said cylindrical extension and positioned to the other side of said jacket core structure from said cylindrical extension, said part seating on said projection.

15. In a mold for casting an internal combustion engine cylinder block having ports in the cylinder walls, a cope and drag formed of green sand and cooperating to provide a mold cavity, a core assembly within said mold cavity and including an outer core portion having a cylindrical extension associated therewith and spaced within said cavity, said assembly including aplurality of additional core portions cooperating with said cylindrical extension of said outer core portion to provide a cylindrical surface, said assembly further including a jacket core structure lying Within said mold cavity and radially spaced from said cylindrical surface formed by said cylindrical extension and said additional core portion, one of said additional core portions having oppositely extending port shaped projections associated therewith and extending through said jacket core structure, said outer core portion having an inwardly extending port concentric with said cylindrical extension and extending into engagement with the projections carried by said additional core portion, said inwardly extending port being radially spaced from said cylindrical extension to receive a portion of said jacket core structure.

ANDRE J. MEYER. 

